Is this the only program that does it? Does procexp from sysinternals work? Can you run a "Clean" 64 big copy from another machine, if you have it available? chkdsk find anything wrong on the drive that may have corrupted it? Antivirus/spybot find anything suspicious on the system?
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Bart SilverstrimDec 7 '09 at 14:37

Just wanted to add that procexp and taskmanager works. However, we have an in-house tool that uses tasklist to check for duplicate processes of a certain type and takes appropriate action. This just happened one day and I don't know why shrugs
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Glen Y.Dec 22 '09 at 21:19